Thermoplastic prepreg based foam product

ABSTRACT

A system for manufacturing a thermoplastic prepreg product includes a belt or conveyor, a prepreg applicator that positions a thermoplastic prepreg atop the belt or conveyor, a foam applicator that applies a foam mixture atop the thermoplastic prepreg, a heating mechanism that heats the thermoplastic prepreg and the foam mixture to cause the foam mixture to react atop the thermoplastic prepreg, and a laminator that is configured to press the thermoplastic prepreg and foam mixture to control a thickness of the resulting thermoplastic prepreg product. The thermoplastic prepreg includes a fabric, mat, or web of fibers and a thermoplastic material that is impregnated within the fabric, mat, or web of fibers. The thermoplastic material is formed from in situ polymerization of monomers and oligomers. The foam mixture includes an isocyanate, a polyol blend, and a blowing agent.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Division of pending U.S. application Ser. No.16/833,794 filed Mar. 30, 2020. The entire contents of theabove-identified application is incorporated by reference for allpurposes.

BACKGROUND

Reinforced thermoplastic materials are gaining interest in the compositeindustry due to their superior properties such as impact resistance,thermoformability, and recyclability, as compared to thermoset sheets.Some thermoplastic reinforced materials are made with fabrics, which areformed by weaving fiber bundles or rovings together. Other thermoplasticreinforced materials are made with fiber mats that have randomlyoriented fibers. Rigid polyurethane and polyisocyanurate foams areusually made in a continuous lamination process in which the foamingredients are poured atop a facer material and the foam is allowed torise and is cured in a heated laminator. Rigid polyurethane andpolyisocyanurate foams are commonly used as insulation boards in variousapplications, such as homes, industrial buildings, and the like.

BRIEF SUMMARY

The embodiments described herein provide thermoplastic prepreg basedfoam products, and specifically systems and methods for making the same.According to one aspect, a system for manufacturing a thermoplasticprepreg product includes a belt or conveyor mechanism, a prepregapplicator, a foam applicator, a heating mechanism, and a laminator. Theprepreg applicator is configured so that a thermoplastic prepreg ispositioned atop the belt or conveyor mechanism and the belt or conveyormechanism is configured to move the thermoplastic prepreg distally alongthe system. The thermoplastic prepreg includes a fabric, mat, or web offibers, in which fibers of the fabric, mat, or web have an averagelength of 0.5 inches or greater and a thermoplastic material that isimpregnated within the fabric, mat, or web of fibers. The thermoplasticmaterial is polymerized from monomers and oligomers in which greaterthan 90% of the monomers or oligomers react to form the thermoplasticmaterial.

The foam applicator is configured to apply a foam mixture atop thethermoplastic prepreg as the thermoplastic prepreg is moved passed thefoam applicator via the belt or conveyor mechanism. The foam mixturecomprises an isocyanate, a polyol blend, and a blowing agent. Theheating mechanism is configured to heat the thermoplastic prepreg andthe foam mixture to cause the foam mixture to react atop thethermoplastic prepreg and form a foam core bonded with the thermoplasticprepreg. The laminator is configured to press the thermoplastic prepregand foam mixture to control a thickness of the thermoplastic prepregproduct.

In some embodiments, the system also includes a second prepregapplicator that is configured so that a second thermoplastic prepreg ispositioned atop the foam mixture after the foam mixture is applied atopthe thermoplastic prepreg. In such embodiments, the foam mixture issandwiched between opposing thermoplastic prepreg layers. The foam coremay consist of polyurethane foam having a foam density of 2 pounds percubic feet (pcf) or less and a thickness of 2 inches or more, or mayconsist of polyisocyanurate foam having a foam density of 2 pounds percubic feet (pcf) or more and a thickness or 2 inches or less. In someembodiments, the thermoplastic material is fully impregnated through thefabric, mat, or web of fibers and forms a barrier such that the foammixture does not impregnate or penetrate into fibers of the fabric, mat,or web of fibers when the foam mixture is applied atop the thermoplasticprepreg. In other embodiments, the thermoplastic material is partiallyimpregnated within the fabric, mat, or web of fibers such that thethermoplastic material is impregnated within a first portion of fibersof the fabric, mat, or web of fibers and a second portion of fibers ofthe fabric, mat, or web of fibers is free of the thermoplastic material.In such embodiments, the system is configured to apply the foam mixtureatop the thermoplastic prepreg so that the foam mixture impregnates orpenetrates into the second portion of fibers of the fabric, mat, or webof fibers that is free of the thermoplastic material.

In some embodiments, the thermoplastic prepreg has a surface having amean roughness of at least 5 micrometers, such that reacting the foammixture atop the thermoplastic prepreg facilitates in mechanicallycoupling the foam core to the thermoplastic prepreg. In someembodiments, the system includes a primer applicator that is configuredto apply a primer atop the thermoplastic prepreg prior to application ofthe foam mixture atop the thermoplastic prepreg. The primer facilitatesin adhering the foam core to the thermoplastic prepreg. In someembodiments, the thermoplastic prepreg includes a thin adhesive filmthat is positioned atop the thermoplastic prepreg, in which the thinadhesive film promotes bonding between the thermoplastic prepreg and thefoam core. In some embodiments, the thermoplastic material consistsessentially of polyamide and the polyamide is adhered to the foam corewithout using a primer or other adhesion promoter.

In some embodiments, the system also includes a prepreg heatingmechanism that is configured to heat the thermoplastic prepreg prior toapplication of the foam mixture atop the thermoplastic prepreg. In suchembodiments, the prepreg heating mechanism may be configured to heat thethermoplastic prepreg above a glass transition temperature of thethermoplastic material and below a melting temperature of thethermoplastic material. The fabric, mat, or web of fibers may includeglass fibers, carbon fibers, basalt fibers, metal fibers, ceramic fiber,natural fibers, synthetic organic fibers, aramid fibers, inorganicfibers, or combinations thereof. The thermoplastic material may includepolyamides, such as polyamide 6 and polyamide 12, polyethyleneterephthalate (PET), polybutylene terephthalate (PBT), polycarbonate(PC), thermoplastic polyurethane (TPU), poly(methyl methacrylate)(PMMA), or combinations thereof. The thermoplastic prepreg may have avoid content of less than 3%.

According to another aspect, a method of forming a thermoplastic prepregproduct includes positioning a thermoplastic prepreg atop a belt orconveyor and pouring a foam mixture onto a top surface of thethermoplastic prepreg. The thermoplastic prepreg includes a fabric, mat,or web of fibers, in which the fibers have an average length of 0.5inches or greater and a thermoplastic material that is impregnatedwithin the fabric, mat, or web of fibers. The thermoplastic material ispolymerized from monomers and oligomers in which greater than 90% of themonomers or oligomers react to form the thermoplastic material. The foammixture includes an isocyanate, a polyol blend, and a blowing agent. Themethod also includes heating the thermoplastic prepreg and the foammixture to react the foam mixture on the top surface of thethermoplastic prepreg to form a foam core that is bonded with thethermoplastic prepreg and laminating the thermoplastic prepreg and thefoam mixture as the foam mixture reacts to control a thickness of theresulting thermoplastic prepreg product.

In some embodiments, the method also includes applying a secondthermoplastic prepreg atop the foam mixture after the foam mixture ispoured onto the top surface of the thermoplastic prepreg so that thefoam mixture is sandwiched between opposing thermoplastic prepreglayers. In some embodiments, the method further includes heating thethermoplastic prepreg prior to pouring the foam mixture onto the topsurface of the thermoplastic prepreg. In such embodiments, thethermoplastic prepreg may be heated to above a glass transitiontemperature of the thermoplastic material and below a meltingtemperature of the thermoplastic material.

According to another aspect, a thermoplastic prepreg product includes athermoplastic prepreg that forms a bottom layer of the thermoplasticprepreg product and a foam core positioned atop the thermoplasticprepreg and bonded to the thermoplastic prepreg. The thermoplasticprepreg includes a fabric, mat, or web of fibers, in which the fibershave an average length of 0.5 inches or greater and a thermoplasticmaterial that is impregnated within the fabric, mat, or web of fibers.The thermoplastic material is polymerized from monomers and oligomers inwhich greater than 90% of the monomers or oligomers react to form thethermoplastic material. The foam core is reacted from an isocyanate anda polyol blend. The foam cores includes a blowing agent and a fireretardant.

In some embodiments, the thermoplastic prepreg also includes a secondthermoplastic prepreg that is positioned atop the foam core and that isbonded to the foam core so that the foam core is sandwiched betweenopposing thermoplastic prepreg layers. In some embodiments, the foamcore may consist of polyurethane foam having a foam density of 2 poundsper cubic feet (pcf) or less, an R-value of at least 5.7 per inch, and acompressive strength of at least 20 pounds per square inch (psi). Inother embodiments, the foam core may consist of polyisocyanurate foamhaving a foam density of 2 pounds per cubic feet (pcf) or more, anR-value of at least 4.0 per inch, and a compressive strength of at least25 pounds per square inch (psi). The thermoplastic material may be fullyimpregnated through the fabric, mat, or web of fibers and may form abarrier between the fabric, mat, or web of fibers and the foam core sothat foam material of the foam core does not impregnate or penetrateinto fibers of the fabric, mat, or web of fibers. Alternatively, thethermoplastic material may be partially impregnated within the fabric,mat, or web of fibers so that the thermoplastic material is impregnatedwithin a first portion of fibers of the fabric, mat, or web of fibersand a second portion of fibers of the fabric, mat, or web of fibers isfree of the thermoplastic material. In such embodiments, a foam materialof the foam core may be impregnated within the second portion of fibersof the fabric, mat, or web of fibers.

The thermoplastic prepreg may have a surface having a mean roughness ofat least 5 micrometers at an interface between the thermoplastic prepregand the foam core. A primer may be positioned between the thermoplasticprepreg and the foam core. The primer may adhere the thermoplasticprepreg to the foam core. A thin adhesive film may be positioned betweenthe thermoplastic prepreg and the foam core. The thin adhesive film maypromote bonding between the thermoplastic prepreg and the foam core. Thethermoplastic material may consist essentially of polyamide and thepolyamide may be adhered to the foam core without using a primer orother adhesion promoter. The fabric, mat, or web of fibers may includeglass fibers, carbon fibers, basalt fibers, metal fibers, ceramic fiber,natural fibers, synthetic organic fibers, aramid fibers, inorganicfibers, or combinations thereof. The thermoplastic material may compriseor consist of polyamides, such as polyamide 6 and polyamide 12,polyethylene terephthalate (PET), polybutylene terephthalate (PBT),polycarbonate (PC), thermoplastic polyurethane (TPU), poly(methylmethacrylate) (PMMA), or combinations thereof. The thermoplastic prepregmay have a void content of less than 3%.

BRIEF DESCRIPTION OF THE DRAWINGS

The present technology is described in conjunction with the appendedfigures:

FIG. 1 illustrates a system for manufacturing a thermoplastic prepregbased foam product or foam composite board.

FIG. 2 illustrates a foam composite board that is manufactured using thesystem of FIG. 1 .

FIG. 3 illustrates a method of forming a thermoplastic prepreg basedfoam product or foam composite board.

In the appended figures, similar components and/or features may have thesame numerical reference label. Further, various components of the sametype may be distinguished by following the reference label by a letterthat distinguishes among the similar components and/or features. If onlythe first numerical reference label is used in the specification, thedescription is applicable to any one of the similar components and/orfeatures having the same first numerical reference label irrespective ofthe letter suffix.

DETAILED DESCRIPTION

The embodiments described herein are directed to fully impregnatedthermoplastic prepreg based foam products. The thermoplastic prepregbased foam products typically include a thermoplastic prepreg that ispositioned on at least one side of the foam product. In manyembodiments, the foam product includes a pair of thermoplastic prepregsthat are positioned on opposite surfaces of the foam product. A foammaterial is typically positioned in between the thermoplastic prepregsand forms a foam core that is sandwiched between the thermoplasticprepregs. The thermoplastic prepregs typically include either continuousfibers in a fabric form, or long fibers (e.g., fibers having fiberlengths of 0.5 inches or more) in a mat or mesh form. The thermoplasticprepregs provide significant strength, stiffness, and impact resistanceto the foam core that is sandwich between the thermoplastic prepregs.The thermoplastic prepreg based foam products are typically lightweightdue to the low density of the foam core. The foam core may providesignificant thermal insulation properties as well. The combination ofhigh strength, lightweight, and thermal insulation value renders thethermoplastic prepreg based foam products ideal for structuralinsulation applications.

An exemplary foam material that may be used in the foam core ispolyurethane or polyisocyanurate foam, which has been widely used toinsulate roofs and walls of commercial and industrial buildings due toits excellent thermal insulation, flame resistance, and mechanicalproperties. The excellent flame resistance is due in part to theformation of an isocyanurate trimer during the foaming process. The foamdensity of the polyurethane or polyisocyanurate foam can vary over awide range and is mainly controlled by an amount of blowing agent thatis used during formulation of the foam. Low density foam, which is foamhaving a density of 2 lbs per cubic foot (pcf) or less, usually providesexcellent thermal insulation performance due to having a high closedcell content and due to the blowing agent employed, such as pentane,which has a low thermal conductivity. High density foam, which is foamhaving a density greater than 2 pcf, provides excellent mechanicalproperties, such as excellent shear, compressive, and impact strength.In addition to polyurethane and polyisocyanurate foams, other foamedpolymer materials can be used in the foam core as well, includingpolystyrene (XPS and EPS), polyolefin (PE and/or PP and/or EPDM foam),polyester, polyimide, polymethacrylamide, phenolic foam.

Conventional polyurethane or polyisocyanurate foam products do notinclude thermoplastic prepreg outer layers. The fiber reinforcedthermoplastic prepreg outer layers that are used in the embodimentsdescribed herein result in the thermoplastic prepreg based foam productshaving substantially greater strength and stiffness properties incomparison with conventional polyurethane or polyisocyanurate foamproducts. In most instances, the foam material does not impregnate intothe thermoplastic prepreg due to the thermoplastic material being fullyimpregnated within the prepreg. In contrast, conventional polyurethaneor polyisocyanurate foam products commonly include a substantial amountof foam material impregnated into the fiber materials that are attachedto the foam products, such as common wet-laid nonwoven fiber mat facermaterials.

The substantially increased mechanical properties of the thermoplasticprepreg based foam products render the products suitable for structuralapplications. In contrast to conventional polyurethane orpolyisocyanurate foam products, the thermoplastic prepreg based foamproducts described herein may be relatively difficult to cut and/orscore. However, the thermoplastic prepreg based foam products may besubstantially more durable and resistant to impact or other damage.

The term “thermoplastic” as used herein refers to polymer materials inwhich essentially no crosslinking, or minimal cross linking occurs. Thenegligible crosslinking enables the material to be heated to above amelting point of the thermoplastic material and formed into a desiredshape. Thermoplastic materials as used herein may be formed via in situpolymerization of monomers or oligomers. Thermoplastic materials mayinclude, but are not limited to, polyamides (including PA6 and PA12),polyethylene terephthalate (PET), polybutylene terephthalate (PBT),polycarbonate (PC), thermoplastic polyurethane (TPU), poly(methylmethacylate) (PMMA), or any combination thereof. The monomers and/oroligomers described herein may include any monomer or oligomer thatpolymerizes to form the thermoplastic materials described above, or anycombination of these monomers or oligomers. The embodiments describedherein may be particularly useful for use with TPU and/or polyamidematerials.

In contrast, the term “thermoset” refers to polymer materials in which asubstantial amount or degree of crosslinking occurs. In contrast tothermoplastic materials, thermoset materials are not able to bethermally formed into a desired shape after curing. Thermoset materialsmay be fully polymerized materials or partially polymerized b-stageresins or materials. Partially polymerized b-stage materials mayincrease the flowability of the resin since they are not fullycrosslinked, but these materials often require special handling, such asrefrigeration, and often have an expiration date upon which the b-stagematerial will begin to degrade. Partially polymerized b-stage materialsalso typically require the use of two release liners that are positionedon opposite sides of the composite and that minimize exposure of theb-stage material to air and/or human contact.

The term “fabric” as used herein describes woven fabrics andstitch-bonded non-crimp fabrics. The woven fabrics are materials thatare produced by weaving multiple roving strands together. The termroving as used herein refers to a bundle of fibers that are positionedadjacent one another to form a rope, thread, or cord like component. Infabrics or woven materials, the roving strands are commonly woven sothat a first plurality of strands extend in a first direction (e.g.,weft direction) and a second plurality of strands extend in a seconddirection that is typically orthogonal to the first direction (e.g.,warp direction). Various weaves may be used to form the fabricscontemplated herein, including: plain weaves, twill weaves, satinweaves, multiaxial weaves, or stitch bonding. The term mat as usedherein refers to nonwoven materials. The terms web or mesh may alsorefer to nonwoven materials. Nonwoven fiber mats are commonly formed offibers that are mechanically entangled, meshed together, or chemicallybonded, rather than being woven or stitched. Web or mesh materials aresimilar to nonwoven materials except that the fibers may not bemechanically entangled or chemically bonded, prior to resinimpregnation. Rather, the thermoplastic material may function as thematrix that binds the fibers together.

It should be understood that the terms fabric, mat, web, or mesh, may beused interchangeably in the embodiments described herein and that,unless specifically claimed, the disclosure is not limited to any oneparticular fiber-based product. Accordingly, it is contemplated that theterms may be replaced or changed in any of the embodiments describedherein without departing from the intended scope of the description.Furthermore, the term “fabric, mat, web, or mesh” or “fiber-basedproduct” may be substituted in the description or claims and is intendedto cover any and all fiber-based products or components that aredescribed or contemplated herein.

A common type of fiber that is used in rovings, fabrics, mats, or websis glass fibers, although various other fibers could be used such ascarbon fibers, basalt fibers, metal fibers, ceramic fibers, cellulosicfibers, natural fibers, synthetic organic fibers such as aramid fibers,inorganic fibers, polymer fibers, or combinations thereof. The fibersmay be treated with a sizing composition including coupling agent(s)that promote bonding between fibers and the monomers and/or oligomers.For example, the fibers may be sized with one or more coupling agentsthat covalently bond the monomers and/or oligomers to the fibers.Exemplary coupling agents may include coupling-activator compoundshaving a silicon-containing moiety and an activator moiety. Specificexamples of coupling-activator compounds include2-oxo-N-(3-(triethoxysilyl)propyl)azepane-1-carboxamide. Exemplarycoupling agents may also include blocked isocyanate coupling compoundshaving a silicon-containing moiety and a blocked isocyanate moiety.Exemplary coupling agents may also include coupling compounds having afunctional group that may react with the thermoplastic material to forma covalent bond. Specific example of the coupling compounds having afunctional group include silane coupling agents having amino, epoxy, orureido functional groups.

The thermoplastic prepregs may be formed in a continuous orsemi-continuous process via impregnation of a fabric, mat, or web offibers with a reactive thermoplastic resin and in-situ polymerization toform thermoplastic resin matrix. Reactive thermoplastic resins comprisemonomers or oligomers that can in situ polymerize to form thermoplasticpolymers. The monomers or oligomers comprises lactams (such ascaprolactam, laurolactam, etc.), lactones, cyclic butylene terephthalate(CBT), methyl methacrylate, precursors of thermoplastic polyurethane, ormixtures thereof. Exemplary systems for forming a thermoplastic prepregare further described in U.S. application Ser. No. 15/944,249, filedApr. 3, 2018, entitled “System for Producing a Fully ImpregnatedThermoplastic Prepreg” and in U.S. application Ser. No. 16/172,153,filed Oct. 26, 2018, entitled “System for Producing a Fully ImpregnatedThermoplastic Prepreg”, the entire disclosures of which are incorporatedby reference herein.

The thermoplastic prepregs may also be formed by melt impregnation of afiber reinforcement with thermoplastic resin melts. The thermoplasticresins suitable for melt impregnation comprise polyolefins includingpolypropylene (PP) and high-density polyethylene (HDPE), polyamidesincluding polyamide 6, polyethylene terephthalate (PET), polybutyleneterephthalate (PBT), polycarbonate (PC), polyphthalamide (PPA),acrylonitrile-butadiene-styrene (ABS), PC/ABS, thermoplasticpolyurethane (TPU), polyphenylene sulfide (PPS), acetal(polyoxymethylene or POM), polyethyleneimine (PEI), polyether etherketone (PEEK), polyacrylonitrile, copolyacrylonitriles includingpoly(styrene-co-acrylonitrile) (SAN), or combinations thereof.

A fully impregnated thermoplastic prepreg can be fed continuously ordiscontinuously, such as in a molding process, through a system. Foamingredients, such as a reaction mixture of isocyanate (A side) andpolyols (B side), are directly poured onto the thermoplastic prepreg,typically as the thermoplastic prepreg is moved underneath a foamapplicator. The foam rises or expands and forms a strong bond with thethermoplastic prepreg. A second thermoplastic prepreg is typicallypositioned atop the foam material after the foam materials is pouredatop the first thermoplastic prepreg. In such embodiments, the foammaterial is sandwiched between two thermoplastic prepreg layers. Thesecond thermoplastic prepreg may be applied atop the foam materialbefore, during, or after the foam has risen and expanded. The foammaterial forms a strong bond with both the first and secondthermoplastic prepregs. The thermoplastic prepreg(s) and foam materialare typically fed through a heated laminator, which cures the foammaterial and presses on the thermoplastic prepreg(s) and foam materialto control a thickness of the resulting foam product. One or moreadditives may be added to the foam core or thermoplastic prepregs. Forexample, the foam core and/or thermoplastic prepregs may include a fireretardant, filler, pigment, and the like. Production speeds formanufacturing the thermoplastic prepreg based foam product can exceed100 feet per minute (fpm) and in some instances can exceed 200 fpm.

The resulting product is a thermoplastic prepreg based foam board, ormore simply a foam composite board, that includes a foam core and athermoplastic prepreg on one or both outer surfaces. The thermoplasticprepreg based foam board is lightweight and strong and may beparticularly suitable for use in refrigerated trucks and railcars (e.g.,wall/floor/ceiling), ocean liner container, recreational vehicles, windenergy (e.g., windmill blade), temporary/emergency housing, such asafter a hurricane, and any structural application that desires highstrength, lightweight, and/or thermal insulation.

Having described several aspects of the embodiments generally,additional features and aspects will be readily apparent in view of thedescription of the drawings provided herein below.

Referring to FIG. 1 , illustrated is a system 100 for manufacturing athermoplastic prepreg based foam product or foam composite board 140.For ease in describing the embodiments, the thermoplastic prepreg basedfoam product will be referred to hereinafter as a foam composite board140. The system 100 is configured to operate in a continuous process.The term continuous process means that the materials (e.g.,thermoplastic prepreg(s) and foam material) are constantly moved betweenthe various components of the system 100 in an uninterrupted orminimally interrupted state. The continuous process results in the quickformation of the foam composite board 140. For example, productionspeeds of the foam composite board 140 can exceed 100 feet per minute(fpm) and in some instances can exceed 200 fpm.

The system 100 includes a roller 102 (hereinafter roller 102) aboutwhich a thermoplastic prepreg 104 is wound. The roller 102 functions asa prepreg applicator by unrolling the thermoplastic prepreg 104 atop abelt or conveyor mechanism 112. The belt or conveyor 112 is configuredto move the thermoplastic prepreg 104 distally along the system. Thethermoplastic prepreg 104 has a width that is generally equivalent to awidth of the belt or conveyor 112, or slightly less than the width ofthe belt or conveyor 112. The thermoplastic prepreg 104 has a lengththat is defined by a desired length of the foam composite board 140. Thethermoplastic prepreg 102 includes a fabric, mat, or web of fibers, inwhich fibers of the fabric, mat, or web have an average length of 0.5inches or greater. The thermoplastic prepreg 104 also includes athermoplastic material that is impregnated within the fabric, mat, orweb of fibers. The thermoplastic material is formed from in situpolymerization of monomers and oligomers, in which greater than 90% ofthe monomers or oligomers react to form the thermoplastic material. Thethermoplastic prepreg 104 typically has a void content of less than 3%.

In some embodiments, the roller 102 may be replaced by a mechanism thatis designed to position separate thermoplastic prepreg sheets onto thebelt or conveyor mechanism 112 at certain defined time intervals. Theseparate thermoplastic prepreg sheets may be positioned onto the belt orconveyor mechanism 112 so that adjacent thermoplastic prepreg sheetshave minimal gaps between each sheet.

The roller 102 is positioned so that the thermoplastic prepreg 104 isunwound from the roller 102 and is moved or pulled to a foam applicator120 that is configured to apply a foam mixture 122 atop thethermoplastic prepreg 104 as the thermoplastic prepreg 104 is movedpassed the foam applicator 120 via the belt or conveyor 112. The foamapplicator 120 is configured to apply the foam mixture 122 so that thefoam mixture 122 extends across the entire width of the thermoplasticprepreg 104. The foam mixture typically includes an A side material(e.g., an isocyanate) and a B side material (e.g., a polyol blend) thatreact to form the foam material. The A side material and B side materialmay vary based on the foam material that is desired to be formed. Themixture 122 may include other materials, such as a blowing agent, fireretardant, filler material, and the like. The mixture 122 is poureddirectly onto the thermoplastic prepreg 104. The foam 124 rises orexpands atop the thermoplastic prepreg 104 and forms a strong bond withthe thermoplastic prepreg.

Various means may be employed to promote bonding between thethermoplastic prepreg 104 and the foam material 124. In one embodiment,a top surface of the thermoplastic prepreg 104 may have a mean roughnessof at least 5 micrometers. Mean Roughness (Ra) is an arithmetic averagevalue of the filtered roughness profile determined from deviations aboutthe center line within the evaluation length, which may be calculatedusing a known mathematical equation. In such embodiments, reacting thefoam mixture 122 atop the thermoplastic prepreg 104 may facilitate inmechanically coupling the foam material 124, or foam core, to thethermoplastic prepreg 104. The roughness in the top surface may beinduced, imprinted, or otherwise transferred onto the top surface, andthe bottom surface if desired, by employing a belt or conveyor having amirrored roughness and by pressing the top or bottom surface duringmanufacturing of the thermoplastic prepreg 104. For example, the beltsor conveyors in the systems described in the '249 and '153 Applicationsincorporated by reference herein may have a surface that mirrors adesired roughness of the top or bottom surface of the thermoplasticprepreg 104. In other embodiments, the roughness may be induced in apost manufacturing process by using a grinding or abrasion mechanism.

In another embodiment, a primer may be applied to the top surface of thethermoplastic prepreg 104 to facilitate in adhering the foam material124 to the thermoplastic prepreg 104. In such embodiments, the system100 may include a primer applicator (not shown) that is configured toapply a primer atop the thermoplastic prepreg 104 prior to applicationof the foam mixture 122 to the thermoplastic prepreg 104. In otherinstances, the primer could be applied elsewhere, such as duringmanufacturing of the thermoplastic prepreg 104 or shortly thereafter. Inyet another embodiment, a thin adhesive film may be applied atop thethermoplastic prepreg 104. The thin adhesive film may promote bondingbetween the thermoplastic prepreg 104 and the foam material 122. Thesystem 100 may include an adhesive film applicator (not shown) or theadhesive film may be pre-applied to the thermoplastic prepreg 104.Exemplary primers include Duralon, which is manufactured by DuromerProducts Pty Ltd, and a polyamide primer manufactured by Tamiya. Anexemplary adhesive film includes BONDiT, which is manufactured byRELTEK.

In a specific embodiment, the thermoplastic material comprises, consistsof, or consists essentially of polyamide and the polyamide is adhered tothe foam material 124 without using a primer or other adhesion promoter.Polyamide is a difficult substrate to bond due to its hydrophobicity andpoor surface wettability (low surface energy). In the isocyanurate rangedescribed herein, it would be expected that polyamide would not adherewell to the foam material 124 since it is known that the adhesion ofpolyamide to isocyanurate is not significant. More specifically, theamount of polyurethane in the foam material 124 is not overlysignificant because of the addition of isocyanurate for rigidity andfire resistance purposes, which significantly weakens the adhesionbetween the thermoplastic prepreg 104 and foam material 124.Surprisingly, however, in formation of a polyamide prepreg based foamcomposite board 140 as described herein, the polyamide adheredexceptionally well to the foam material 124 so that a primer or otheradhesive promoter was not required. To enhance the ability of thepolyamide to bond to the foam material 124, the polyamide may be surfacetreated, such as via a plasma or corona treatment. In applications whereenhanced fire resistance is not a concern, the amount of isocyanuratecan be reduced and/or the amount of polyurethane can be increased toenhance the bonding between the thermoplastic prepreg 140 and the foammaterial 124.

In some embodiments, the thermoplastic material is fully impregnatedthrough the fabric, mat, or web of fibers of the thermoplastic prepreg104. In such embodiments, the thermoplastic material forms a barrier sothat the foam mixture 122 does not impregnate or penetrate into fibersof the fabric, mat, or web of fibers when the foam mixture 122 isapplied atop the thermoplastic prepreg 104. Stated differently, when thethermoplastic material is fully impregnated through thermoplasticprepreg's fabric, mat, or web of fibers, there is no impregnation of thefoam material 124 into the fabric, mat, or web of fibers so that thefibers remain free of the foam material 124 and do not contact, orminimally contact, the foam material 124.

In other embodiments, the thermoplastic material of the thermoplasticprepreg 104 may partially impregnate the fabric, mat, or web of fibers.In such embodiments, the thermoplastic material may be impregnatedwithin a first fiber portion of the fabric, mat, or web of fibers and asecond fiber portion of fibers of the fabric, mat, or web of fibers maybe free of the thermoplastic material. The first fiber portion of thefabric, mat, or web of fibers may have a void content of less than 3% asdescribed herein while the second fiber portion is free of thermoplasticmaterial entirely. In such embodiments, the second fiber portion may bepositioned atop the belt or conveyor 112 so that the foam mixture 122 isapplied or poured atop the second fiber portion and impregnates orpenetrates into fibers of the second fiber portion. Since the secondfiber portion of the fabric, mat, or web of fibers is free of thethermoplastic material, the second fiber portion does not include abarrier material that prevent impregnation or penetration of the foammixtures 122 and/or foam material 124 into the fibers. Impregnation ofthe foam mixture 122 and/or foam material 124 into the second fiberportion of the fabric, mat, or web of fibers may promote bonding betweenthe thermoplastic prepreg 104 and foam material 124 by mechanicallycoupling the two materials. A partially impregnated thermoplasticprepreg may be preferred because it enables a physical bonding orcoupling of the thermoplastic prepreg 104 and foam material 124.

The system 100 typically includes a second roller 106 that functions asa second prepreg applicator by applying or positioning a secondthermoplastic prepreg 108 atop the foam mixture 122 after the foammixture 122 is applied atop the first thermoplastic prepreg 104. In suchembodiments, the system 100 sandwiches the foam mixture 122 betweenopposing thermoplastic prepreg layers, 104 and 108. The secondthermoplastic prepreg 108 typically has a width that mirrors the widthof the first thermoplastic prepreg 104 so that the second thermoplasticprepreg 108 extends across an entire width of the foam material 124 andacross an entire length of the resulting foam composite board 140. Thesecond thermoplastic prepreg 108 may have a composition and/orconstruction (e.g., fully or partially impregnated) as described hereinand/or that mirrors or matches a composition and/or construction of thefirst thermoplastic prepreg 104. In other embodiments, the firstthermoplastic prepreg 104 and the second thermoplastic prepreg 108 maydiffer in composition and/or construction so that the foam material 124is disposed between differing thermoplastic prepreg outer layers. Thefirst thermoplastic prepreg 104 may be designed to provide a first setof properties (e.g., increased strength) while the second thermoplasticprepreg 108 is designed to provide a second set of properties (e.g.,bondability). In some embodiments, the foam composite board 140 mayinclude a thermoplastic prepreg 104 on one of its surfaces and anentirely different outer material on the opposite surface. For example,the different outer material could be a nonwoven material, a paperfacer, an aluminum foil facer, Kraft paper laminate facer, a scrim, ametal panel, and the like.

The system 100 may include a prepreg heating mechanism 162 that isconfigured to heat the thermoplastic prepreg 104 prior to application ofthe foam mixture 122 atop the thermoplastic prepreg 104. In someinstances, the thermoplastic prepreg 104 may be heated to around 100Fahrenheit or more to ensure that the foam mixture 122 is not applied toa cold surface. In some instances, the prepreg heating mechanism 162 maybe configured to heat the thermoplastic prepreg 104 to near or above aglass transition temperature of the thermoplastic material whilemaintaining the temperature below a melting temperature of thethermoplastic material. Heating the thermoplastic prepreg 104 to near orabove the glass transition temperature may be particularly useful whenit is desired to soften the thermoplastic material in order to removeany shape memory that may be induced during manufacturing or transportof the thermoplastic prepreg 104. For example, a curl or bend in thethermoplastic prepreg 104 may be induced due to storage and/or transportof the thermoplastic prepreg 104. In such instances, it may bebeneficial to soften the thermoplastic prepreg 104 to remove or minimizethe shape memory and thereby minimize or prevent delamination of thethermoplastic prepreg 104 and foam material 124 after manufacturing. Theheating mechanism 162 may heat the thermoplastic prepreg 104 to near orabove about ⅔ of the melting temperature of the thermoplastic material.In some embodiments, the heating mechanism 162 may heat thethermoplastic prepreg 104 to between 100 and 400 degrees F., andpreferably between 200 and 300 degrees F.

The system 100 may also include a second heating mechanism 164 that isconfigured to heat the second thermoplastic prepreg 108 in a mannersimilar to the first heating mechanism 164. In such embodiments, thesystem 100 may heat both the first and second thermoplastic prepregs,104 and 108. In other instances, the system 100 may only be configuredto heat the first or second thermoplastic prepreg, 104 and 108, asneeded.

Heating the thermoplastic prepreg 104 to the temperatures describedherein is substantially higher than typical ranges that are used forconventional foam composite board outer layer materials, such asconventional facer materials, since these higher temperature ranges donot provide any benefit for conventional foam composite board outermaterials. Heating the thermoplastic prepreg 104 to these highertemperatures may offer other beneficial properties, such as enhancedadhesion or reduced reaction time of the foam material.

The system 100 also includes a heating mechanism that is configured toheat the thermoplastic prepreg(s), 104 and/or 108, and the foam mixture122 to cause the foam mixture 122 to react atop the thermoplasticprepreg 104 and form the foam material 124 or foam core that is bondedwith the thermoplastic material. The system further includes a laminator130 that is configured to press the thermoplastic prepreg 102 and foammixture 122 to control a thickness of the resulting foam composite board140. The heating mechanism and laminator 130 are typically combined intoa single system, although separate systems or components may be used asdesired. The heating mechanism is typically heated to between 130 and190 Fahrenheit, which causes the foam mixture 122 to react atop thethermoplastic prepreg 104.

The system 100 may also include a cutting mechanism 150 that is designedto cut the foam composite board 140 that exits the laminator 130. Thecutting mechanism 150 cuts the foam composite board 140 to a desiredlength. The system may also include a cooling mechanism (not shown) thatis designed to cool the foam composite board 140 prior to cutting thefoam composite board 140 with the cutting mechanism 150. The system 100also typically includes one or more guide components (not shown) thatroute or direct the thermoplastic prepregs, 104 and 108, from therespective rollers, 102 and 106, to the components of the system 100.The system 100 may include additional guides (not shown) that arepositioned distally of the laminator 130 that guide or route the foamcomposite board 140 to the cutting mechanism 150 and elsewhere asrequired.

The foam composite board 140 that is produced via the system 100 mayinclude a high density or low density foam depending on the intendedapplication of the foam composite board 140. In one embodiment, the foamcomposite board 140 has a foam core that consists of polyurethane foamhaving a foam density of 2 pounds per cubic feet (pcf) or less and athickness of 2 inches or more. This foam composite board 140 may beparticularly suited for applications that require appreciable thermalinsulation properties. In another embodiment, the foam composite board140 may have a foam core that consists of polyisocyanurate foam having afoam density of 2 pounds per cubic feet (pcf) or more and a thickness or2 inches or less. This foam composite board 140 may be particularlysuited for applications where enhanced structural property is requiredand thermal insulation may be of little concern or of secondary concern.Other foam composite board 140 compositions and/constructions and otherfoam core materials may be formed with the system 100 described herein.For example, the foam composite board may be a thin board (i.e., lessthan 2 inches) that includes a low density foam (i.e., 2 pcf or less) ormay be a thick board (i.e., greater than 2 inches) that includes a highdensity foam (i.e., 2 pcf or more). The foam composite board may have aflame spread index (FSI) of 25 or less, as determined according to ASTME84 test method. In addition, although the system 100 is described asusing a thermoplastic prepeg, 104 and/or 108, in some embodiments it maybe preferred to use a thermoset prepreg, which is a fabric, mat, or webof fibers that is impregnated with a thermoset material. The thermosetprepreg may be unwound from the respective roller(s) and passed throughthe system as described herein. The use of a thermoset prepreg may beparticularly useful when the foam core is made of polyurethane. Thepolyurethane foam may have a chemistry that bonds easily with thethermoset prepreg material and the combination of these materials may bepreferred in some applications.

Referring to FIG. 2 , illustrated is a foam composite board 200 (i.e., athermoplastic prepreg product) that includes a thermoplastic prepreg 202forming a bottom layer of the foam composite board 200. The foamcomposite board 200 has a length and a width that is defined by thesystem that manufactured the foam composite board 200, and more commonlythat is defined based on an intended application of the foam compositeboard 200. The thermoplastic prepreg 202 includes a fabric, mat, or webof fibers, in which the fibers have an average length of 0.5 inches orgreater. For illustrative purposes, the thermoplastic prepreg 202 isillustrated as having dispersed fibers, although the fibers may be inthe form of a fabric, mat, web, or other configuration as a person ofskill will readily understand.

A thermoplastic material is impregnated within the fabric, mat, or webof fibers such that the thermoplastic prepreg 202 has a void content ofless than 3%. The thermoplastic material is formed via in situpolymerization of monomers and oligomers in which greater than 90% ofthe monomers or oligomers react to form the thermoplastic material. Afoam core 204 is positioned atop the thermoplastic prepreg 202 and isbonded to the thermoplastic prepreg so that the foam core 204 extendsacross the length and width of the thermoplastic prepreg 202. The foamcore is formed from an isocyanate and a polyol blend. In someembodiments, the polyol blend may have a functionality of at least 2.0and/or a hydroxyl number in the range of 100 to 1200. The foam core 204may also include a blowing agent, a fire retardant, and/or otheradditives as desired. In some embodiments, the isocyanate and the polyolblend are reacted so that the foam core 204 has an isocyanate indexequivalent between 100 and 350, while in other embodiments the foam core204 has an isocyanate index greater than 300. In some embodiments, thefoam composite board 200 includes a second thermoplastic prepreg 206that is positioned atop the foam core 204 and that is bonded to the foamcore so that the foam core 204 is sandwiched between opposingthermoplastic prepreg layers, 202 and 206. The second thermoplasticprepreg 206 extends across a length and width of the foam core 204.

In one embodiment, the foam core 204 is a low density foam. For example,the foam core may consist of, or consist essentially of, polyurethanefoam having a foam density of 2 pounds per cubic feet (pcf) or less, anR-value of at least 5.7 per inch, and a compressive strength of at least20 pounds per square inch (psi). In another embodiment, the foam core204 is a high density foam. For example, the foam core may consist of,or consist essentially of, polyisocyanurate foam having a foam densityof 2 pounds per cubic feet (pcf) or more, an R-value of at least 4.0 perinch, and a compressive strength of at least 25 pounds per square inch(psi). Regardless of the use of a high or low density foam, the foamcomposite board 200 may have a compressive strength of at least 20 psi.

In some embodiment, the thermoplastic material of at least one of thethermoplastic prepregs, 202 and 206, is fully impregnated through thefabric, mat, or web of fibers and forms a barrier between the fabric,mat, or web of fibers and the foam core 204 such that foam material ofthe foam core 204 does not impregnate or penetrate into fibers of thefabric, mat, or web of fibers. The thermoplastic material may fullyimpregnate the first thermoplastic prepreg 202, the second thermoplasticprepreg 206, or both thermoplastic prepregs as desired. In such anembodiment, the foam material essentially only contacts thethermoplastic material (e.g., polyamide) on the surface of thethermoplastic prepreg, 202 and 206, and is bonded therewith so that thefibers of the thermoplastic prepreg do not contact, or minimallycontact, the thermoplastic material. The thermoplastic material may bonddirectly to the polyamide as described herein, or an adhesion promotermay be used to increase the adhesion between the materials.

In another embodiment, the thermoplastic material of at least one of thethermoplastic prepregs, 202 and 206, is partially impregnated within thefabric, mat, or web of fibers. In such embodiments, the thermoplasticmaterial may only be impregnated within a first portion of fibers of thefabric, mat, or web of fibers so that a second portion of fibers of thefabric, mat, or web of fibers remains free of the thermoplasticmaterial. The thermoplastic material may partially impregnate into thefirst thermoplastic prepreg 202, the second thermoplastic prepreg 206,or both thermoplastic prepregs as desired. When the thermoplasticmaterial is partially impregnated within the fabric, mat, or web offibers, the second portion of fibers of the fabric, mat, or web offibers is typically positioned adjacent the foam core 204. In suchembodiments, the foam material of the foam core 204 may be impregnated,or otherwise positioned, within the second portion of fibers of thefabric, mat, or web of fibers. The impregnation of the foam materialinto the fibers of the second portion of the fabric, mat, or web offibers may enhance coupling or bonding of the thermoplastic prepreg(s),202 and/or 206, and the foam core 204. In other embodiments, the firstportion of fibers of the fabric mat or web of fibers may be positionedadjacent the foam core 204 and the second portion of fibers of thefabric, mat, or web of fibers may be positioned opposite the foam core204. In such embodiments, the second portion of fibers of the fabric,mat, or web of fibers may be impregnated with another material, or maybe used for another purpose, such as bonding the foam composite board200 with another component or material, absorbing a liquid, providing adesired outer surface, and the like. In some embodiments, one of thethermoplastic prepregs (e.g., the first thermoplastic prepreg 202) maybe fully impregnated with a thermoplastic material while the otherthermoplastic prepreg (e.g., the second thermoplastic prepreg 206) ispartially impregnated with a thermoplastic material. The thermoplasticmaterials that are used in the first and second thermoplastic prepregs,202 and 206, may be the same material, a different material, or acombination of materials as desired.

In some embodiments, a surface of the thermoplastic prepreg (i.e., thesurface at an interface between the thermoplastic prepreg and the foamcore 204) has a mean roughness of at least 5 micrometers. The roughenedsurface may be induced during formation of the thermoplastic prepreg orsubsequent to formation of the thermoplastic prepreg. A mean roughnessmay be induced in a top surface of the first thermoplastic prepreg 202,a bottom surface of the second thermoplastic prepreg 206, or in both thetop surface of the first thermoplastic prepreg 202 and the bottomsurface of the second thermoplastic prepreg 206.

In some embodiments a primer may be positioned between at least one ofthe thermoplastic prepregs, 202 and 206, and the foam core 204. Theprimer may adhere the thermoplastic prepreg(s), 202 and/or 206, to thefoam material of the foam core 204. In another embodiment, a thinadhesive film may be positioned between at least one of thethermoplastic prepregs, 202 and 206, and the foam core 204. The thinadhesive film may promote bonding between the thermoplastic prepreg(s),202 and/or 206, and the foam material of the foam core 204. In someembodiments, a combination of a primer, a thin adhesive film, and/or aroughened surface may be used to promote bonding between thethermoplastic prepreg(s), 202 and/or 206, and the foam material of thefoam core 204. In contrast, in a specific embodiment, the thermoplasticmaterial may consist of, or consist essentially of, polyamide, and thepolyamide may be adhered to the foam core 204 without using a primer orother adhesion promoter.

The fibers of the first thermoplastic prepreg 202 and the secondthermoplastic prepreg 206 may include any of the fiber materialsdescribed herein, or any other fibers materials. The fibers of the firstthermoplastic prepreg 202 and the second thermoplastic prepreg 206 maybe the same type of fibers, different types of fibers, or a combinationof fibers as desired. Similarly, the thermoplastic material of the firstthermoplastic prepreg 202 and the second thermoplastic prepreg 206 mayinclude any of the thermoplastic materials described herein, or anyother suitable thermoplastic material. The thermoplastic material of thefirst thermoplastic prepreg 202 and the second thermoplastic prepreg 206may be the same thermoplastic material, different thermoplasticmaterials, or a combination of thermoplastic materials as desired. Thefoam material of the foam core 204 may be any of the foam materialsdescribed herein, or any other suitable foam material.

In some embodiments, the first thermoplastic prepreg 202 and/or thesecond thermoplastic prepreg 206 may be replaced by a thermoset prepreg.In such embodiments, the foam core 204 may be sandwiched between twothermoset prepreg layers, or may include a single thermoset prepregpositioned on one of the exterior surfaces. In some embodiments, thefoam core 204 may be sandwiched between a thermoset prepreg and athermoplastic prepreg. The use of a thermoset prepreg layer, or opposingthermoset prepreg layers, may be particularly useful when the foam core204 is made of polyurethane. The polyurethane foam may have a chemistrythat bonds easily with the thermoset prepreg layer(s) and may bepreferred depending on the intended application of the foam compositeboard 200.

Referring to FIG. 3 , illustrated is a method 300 of forming athermoplastic prepreg product or foam composite board. At block 310, athermoplastic prepreg is positioned atop a belt or conveyor. Thethermoplastic prepreg has a length and a width and includes a fabric,mat, or web of fibers, in which the fibers have an average length of 0.5inches or greater and a thermoplastic material that is impregnatedwithin the fabric, mat, or web of fibers. The thermoplastic prepreg hasa void content of less than 3% and the thermoplastic material is formedvia in situ polymerization of monomers and oligomers in which greaterthan 90% of the monomers or oligomers react to form the thermoplasticmaterial. In some embodiments, a thermoset prepreg may be used insteadof a thermoplastic prepreg. A thermoset prepreg may be employed when thefoam core is a made of polyurethane. At block 320, a foam mixture ispoured onto a top surface of the thermoplastic prepreg so that the foammixture extends across the length and width of the thermoplasticprepreg. The foam mixture includes or consists of an isocyanate, apolyol blend, and a blowing agent. At block 330, the thermoplasticprepreg and the foam mixture are heated to react the foam mixture on thetop surface of the thermoplastic prepreg to form a foam core that isbonded with the thermoplastic prepreg. At block 340, the thermoplasticprepreg and the foam mixture are laminated as the foam mixture reacts tocontrol a thickness of the resulting thermoplastic prepreg product.Blocks 330 and 340 may be performed simultaneously via a heatedlaminator, or may be performed separately by different devices ormechanisms.

In some embodiments, the method also includes applying a secondthermoplastic prepreg atop the foam mixture after the foam mixture ispoured onto the top surface of the thermoplastic prepreg. In suchembodiments, the foam mixture is sandwiched between opposingthermoplastic prepreg layers. In some embodiments, a thermoset prepregmay be positioned atop the foam mixture after the foam mixture is pouredonto the top surface of the thermoplastic prepreg or another thermosetprepreg. The second thermoplastic prepreg typically extends across alength and width of the foam mixture and the first thermoplasticprepreg. The method may be used to form a low density foam product, suchas a foam composite board in which the foam core consists of, orconsists essentially of, polyurethane foam having a foam density of 2pounds per cubic feet (pcf) or less and a thickness of 2 inches or more.The method may also be used to form a high density foam product, such asa foam composite board in which the foam core consists of, or consistsessentially of, polyisocyanurate foam having a foam density of 2 poundsper cubic feet (pcf) or more and a thickness of 2 inches or less. Themethod may further be used to produce foam composite boards havingdifferent foam core materials or compositions as desired.

In some embodiments, the thermoplastic material is fully impregnatedthrough the fabric, mat, or web of fibers and forms a barrier such thatthe foam mixture does not impregnate or penetrate into fibers of thefabric, mat, or web of fibers when the foam mixture is poured onto thetop surface of the thermoplastic prepreg. In other embodiments, thethermoplastic material is partially impregnated within the fabric, mat,or web of fibers such that the thermoplastic material is impregnatedwithin a first portion of fibers of the fabric, mat, or web of fibersand a second portion of fibers of the fabric, mat, or web of fibersremains free of the thermoplastic material. In such embodiments, thefirst portion of fibers of the fabric, mat, or web of fibers may have avoid content of less than 3% and the foam mixture may be poured onto thetop surface of the thermoplastic prepreg so that the foam mixtureimpregnates or penetrates into fibers of the second portion of fibers ofthe fabric, mat, or web of fibers.

The top surface of the thermoplastic prepreg may have a mean roughnessof at least 5 micrometers such that reacting the foam mixture on the topsurface of the thermoplastic prepreg facilitates in mechanicallycoupling the foam core to the thermoplastic prepreg. In someembodiments, the method may additionally include applying a primer tothe top surface of the thermoplastic prepreg prior to pouring the foammixture onto the top surface of the thermoplastic prepreg. The primermay facilitate in adhering the foam core to the thermoplastic prepreg.In contrast or in addition, the method may additionally include applyinga thin adhesive film on the top surface of the thermoplastic prepregprior to pouring the foam mixture onto the top surface of thethermoplastic prepreg. The thin adhesive film may also promote bondingbetween the thermoplastic prepreg and the foam core. In contrast, thethermoplastic material may consist essentially of polyamide and thepolyamide may adhere to the foam core without using a primer or otheradhesion promoter.

In some embodiments, the method may additionally include heating thethermoplastic prepreg prior to pouring the foam mixture onto the topsurface of the thermoplastic prepreg. In such embodiments, thethermoplastic prepreg may be heated to above a glass transitiontemperature of the thermoplastic material and below a meltingtemperature of the thermoplastic material.

Example foam mixtures that may be used in forming a foam composite boardare provided below. Numeric values of the A side (i.e., isocyanate) andB side (i.e., polyol blend) materials are provided along with numericvalues for the foam mixture. A high density formulation that produces aroughly 0.5 inch foam core may be as follows:

Component Parts Polyol 100 Cat 1 2 Cat 2 0.3 Cat 3 0.3 Surfactant 2.0Pentane 50/50 i/n 3.75 Water 0.4 Total “B” 108.75 Total “A” (Isocyanate)174.45 Total A + B 283.20 Index 3.00 Ratio 1.60 Total Batch Size (g)250.00

In the table above, the A side material comprised or consisted of anisocyanate that included roughly 174.45 parts. The B side materialconsisted of roughly 100 parts of a polyol blend. In some embodiments,the polyol blend may include roughly 15% of a fire retardant, such asTCPP. The B side also consisted of 3 catalysts, a surfactant (e.g.,VorasurfTM 504), a blowing agent (e.g., Pentane), and water. The B sidehad roughly 108.75 parts such that a mixture of the A side and B sidematerials resulted in a mixture with roughly 283.20 parts. The resultingfoam product has an index of roughly 3.00 and a ratio of 1.60.

A low density formulation that produces a roughly 2.0 inch foam core maybe as follows:

Component Parts Polyol 100 Cat 1 5.0 Cat 2 0.45 Cat 3 0.4 Surfactant 2.0Fire Retardant 12.00 Pentane 50/50 i/n 23.00 Water 0.4 Total “B” 143.25Total “A” (isocyanate) 179.24 Total A + B 322.49 Index 2.7 Ratio 1.25Total Batch Size (g) 198.26

In the table above, the A side material comprised or consisted of anisocyanate that included roughly 179.24 parts. The B side materialconsisted of roughly 100 parts of a polyol blend. The B side alsoconsisted of 3 catalysts, a surfactant, a fire retardant (e.g., TCPP), ablowing agent (e.g., Pentane), and water. The B side had roughly 143.25parts such that a mixture of the A side and B side materials resulted ina mixture with roughly 322.49 parts. The resulting foam product has anindex of roughly 2.70 and a ratio of 1.25.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimits of that range is also specifically disclosed. Each smaller rangebetween any stated value or intervening value in a stated range and anyother stated or intervening value in that stated range is encompassed.The upper and lower limits of these smaller ranges may independently beincluded or excluded in the range, and each range where either, neither,or both limits are included in the smaller ranges is also encompassedwithin the invention, subject to any specifically excluded limit in thestated range. Where the stated range includes one or both of the limits,ranges excluding either or both of those included limits are alsoincluded.

As used herein and in the appended claims, the singular forms “a”, “an”,and “the” include plural referents unless the context clearly dictatesotherwise. Thus, for example, reference to “a method” includes aplurality of such methods and reference to “the glass fiber” includesreference to one or more glass fibers and equivalents thereof known tothose skilled in the art, and so forth. The invention has now beendescribed in detail for the purposes of clarity and understanding.However, it will be appreciated that certain changes and modificationsmay be practice within the scope of the appended claims.

Also, the words “comprise,” “comprising,” “include,” “including,” and“includes” when used in this specification and in the following claimsare intended to specify the presence of stated features, integers,components, or steps, but they do not preclude the presence or additionof one or more other features, integers, components, steps, acts, orgroups.

What is claimed is:
 1. A system for manufacturing a thermoplasticprepreg product, the system comprising: a belt or conveyor mechanism; aprepreg applicator that is configured so that a thermoplastic prepreg ispositioned atop the belt or conveyor mechanism, the belt or conveyormechanism being configured to move the thermoplastic prepreg distallyalong the system, the thermoplastic prepreg having a length and a widthand the thermoplastic prepreg including: a fabric, mat, or web offibers, in which fibers of the fabric, mat, or web have an averagelength of 0.5 inches or greater; and a thermoplastic material that isimpregnated within the fabric, mat, or web of fibers, the thermoplasticmaterial being polymerized from monomers and oligomers in which greaterthan 90% of the monomers or oligomers react to form the thermoplasticmaterial; a foam applicator that is configured to apply a foam mixtureatop the thermoplastic prepreg as the thermoplastic prepreg is movedpassed the foam applicator via the belt or conveyor mechanism, the foamapplicator being configured to apply the foam mixture so that the foammixture extends across the length and width of the thermoplasticprepreg, the foam mixture comprising: an isocyanate; a polyol blend; anda blowing agent; a heating mechanism that is configured to heat thethermoplastic prepreg and the foam mixture to cause the foam mixture toreact atop the thermoplastic prepreg and form a foam core bonded withthe thermoplastic prepreg; and a laminator that is configured to pressthe thermoplastic prepreg and foam mixture to control a thickness of thethermoplastic prepreg product.
 2. The system of claim 1, furthercomprising a second prepreg applicator that is configured so that asecond thermoplastic prepreg is positioned atop the foam mixture afterthe foam mixture is applied atop the thermoplastic prepreg such that thefoam mixture is sandwiched between opposing thermoplastic prepreglayers, wherein the second thermoplastic prepreg extending across alength and width of the foam core.
 3. The system of claim 1, wherein thefoam core consists of polyurethane foam having a foam density of 2pounds per cubic feet (pcf) or less and a thickness of 2 inches or more.4. The system of claim 1, wherein the foam core consists ofpolyisocyanurate foam having a foam density of 2 pounds per cubic feet(pcf) or more and a thickness or 2 inches or less.
 5. The system ofclaim 1, wherein the thermoplastic material is fully impregnated throughthe fabric, mat, or web of fibers and forms a barrier such that the foammixture does not impregnate or penetrate into fibers of the fabric, mat,or web of fibers when the foam mixture is applied atop the thermoplasticprepreg.
 6. The system of claim 1, wherein the thermoplastic prepreg hasa surface having a mean roughness of at least 5 micrometers, such thatreacting the foam mixture atop the thermoplastic prepreg facilitates inmechanically coupling the foam core to the thermoplastic prepreg.
 7. Thesystem of claim 1, further comprising a primer applicator that isconfigured to apply a primer atop the thermoplastic prepreg prior toapplication of the foam mixture atop the thermoplastic prepreg, whereinthe primer facilitates in adhering the foam core to the thermoplasticprepreg.
 8. The system of claim 1, wherein the thermoplastic prepregincludes a thin adhesive film positioned atop the thermoplastic prepreg,the thin adhesive film promoting bonding between the thermoplasticprepreg and the foam core.
 9. The system of claim 1, wherein thethermoplastic material consists essentially of polyamide, and whereinthe polyamide is adhered to the foam core without using a primer orother adhesion promoter.
 10. The system of claim 1, wherein thethermoplastic material is partially impregnated within the fabric, mat,or web of fibers such that the thermoplastic material is impregnatedwithin a first portion of fibers of the fabric, mat, or web of fibersand a second portion of fibers of the fabric, mat, or web of fibers isfree of the thermoplastic material, wherein the system is configured toapply the foam mixture atop the thermoplastic prepreg so that the foammixture impregnates or penetrates into the second portion of fibers ofthe fabric, mat, or web of fibers that is free of the thermoplasticmaterial.
 11. The system of claim 1, further comprising a prepregheating mechanism that is configured to heat the thermoplastic prepregprior to application of the foam mixture atop the thermoplastic prepreg,the prepreg heating mechanism being configured to heat the thermoplasticprepreg above a glass transition temperature of the thermoplasticmaterial and below a melting temperature of the thermoplastic material.12. The system of claim 1, wherein the fabric, mat, or web of fibersinclude glass fibers, carbon fibers, basalt fibers, metal fibers,ceramic fiber, natural fibers, synthetic organic fibers, aramid fibers,inorganic fibers, or combinations thereof.
 13. The system of claim 1,wherein the thermoplastic material comprises polyamides, such aspolyamide 6 and polyamide 12, polyethylene terephthalate (PET),polybutylene terephthalate (PBT), polycarbonate (PC), thermoplasticpolyurethane (TPU), poly(methyl methacrylate) (PMMA), or combinationsthereof.
 14. The system of claim 1, wherein the thermoplastic prepreghas a void content of less than 3%.
 15. A thermoplastic prepreg productcomprising: a thermoplastic prepreg that forms a bottom layer of thethermoplastic prepreg product, the thermoplastic prepreg having a lengthand a width and the thermoplastic prepreg including: a fabric, mat, orweb of fibers, in which the fibers have an average length of 0.5 inchesor greater; and a thermoplastic material that is impregnated within thefabric, mat, or web of fibers, the thermoplastic material beingpolymerized from monomers and oligomers in which greater than 90% of themonomers or oligomers react to form the thermoplastic material; and afoam core positioned atop the thermoplastic prepreg and bonded to thethermoplastic prepreg so that the foam core extends across the lengthand width of the thermoplastic prepreg, the foam core reacted from: anisocyanate; and a polyol blend; wherein: the foam core includes ablowing agent; and the foam core includes a fire retardant.
 16. Thethermoplastic prepreg product of claim 15, further comprising a secondthermoplastic prepreg that is positioned atop the foam core and bondedto the foam core such that the foam core is sandwiched between opposingthermoplastic prepreg layers, the second thermoplastic prepreg extendingacross a length and width of the foam core.
 17. The thermoplasticprepreg product of claim 15, wherein the foam core consists ofpolyurethane foam having a foam density of 2 pounds per cubic feet (pcf)or less, an R-value of at least 5.7 per inch, and a compressive strengthof at least 20 pounds per square inch (psi).
 18. The thermoplasticprepreg product of claim 15, wherein the foam core consists ofpolyisocyanurate foam having a foam density of 2 pounds per cubic feet(pcf) or more, an R-value of at least 4.0 per inch, and a compressivestrength of at least 25 pounds per square inch (psi).
 19. Thethermoplastic prepreg product of claim 15, wherein the thermoplasticmaterial is fully impregnated through the fabric, mat, or web of fibersand forms a barrier between the fabric, mat, or web of fibers and thefoam core such that foam material of the foam core does not impregnateor penetrate into fibers of the fabric, mat, or web of fibers.
 20. Thethermoplastic prepreg product of claim 15, wherein the thermoplasticprepreg has a surface having a mean roughness of at least 5 micrometersat an interface between the thermoplastic prepreg and the foam core. 21.The thermoplastic prepreg product of claim 15, further comprising aprimer positioned between the thermoplastic prepreg and the foam corethat adheres the thermoplastic prepreg to the foam core.
 22. Thethermoplastic prepreg product of claim 15, further comprising a thinadhesive film positioned between the thermoplastic prepreg and the foamcore, the thin adhesive film promoting bonding between the thermoplasticprepreg and the foam core.
 23. The thermoplastic prepreg product ofclaim 15, wherein the thermoplastic material consists essentially ofpolyamide, and wherein the polyamide is adhered to the foam core withoutusing a primer or other adhesion promoter.
 24. The thermoplastic prepregproduct of claim 15, wherein the thermoplastic material is partiallyimpregnated within the fabric, mat, or web of fibers such that thethermoplastic material is impregnated within a first portion of fibersof the fabric, mat, or web of fibers and a second portion of fibers ofthe fabric, mat, or web of fibers is free of the thermoplastic material,and wherein a foam material of the foam core impregnates the secondportion of fibers of the fabric, mat, or web of fibers.
 25. Thethermoplastic prepreg product of claim 15, wherein the fabric, mat, orweb of fibers include glass fibers, carbon fibers, basalt fibers, metalfibers, ceramic fiber, natural fibers, synthetic organic fibers, aramidfibers, inorganic fibers, or combinations thereof.
 26. The thermoplasticprepreg product of claim 15, wherein the thermoplastic materialcomprises polyamides, such as polyamide 6 and polyamide 12, polyethyleneterephthalate (PET), polybutylene terephthalate (PBT), polycarbonate(PC), thermoplastic polyurethane (TPU), poly(methyl methacrylate)(PMMA), or combinations thereof.
 27. The thermoplastic prepreg productof claim 15, wherein the thermoplastic prepreg has a void content ofless than 3%.